Busbar connector with insulative housing and sealing mechanism

Abstract

An electrical busbar connector includes an electrically insulative connector housing with a cavity designed to accommodate an electrical busbar made of a first electrically conductive material and an electrical terminal attached to the busbar, which is composed of a second electrically conductive material distinct from the first. The connector further comprises a busbar seal that ensures a secure seal between the busbar and the connector housing, thereby enhancing the integrity and reliability of the electrical connection. This configuration allows for effective insulation and protection of the busbar and terminal, facilitating efficient electrical connectivity while minimizing potential for electrical faults or environmental contaminant ingress.

1 . An electrical busbar connector, comprising:
 an electrically insulative connector housing having a cavity configured to receive an electrical busbar comprising a first electrically conductive material and an electrical terminal attached to the busbar comprising a second electrically conductive material distinct from the first electrically conductive material; and   a busbar seal configured to seal the busbar to the connector housing.   
     
     
         2 . The electrical busbar connector in accordance with  claim 1 , further comprising:
 a cover configured to enclose the cavity; and   a cover seal configured to seal the cover to the connector housing.   
     
     
         3 . The electrical busbar connector in accordance with  claim 2 , wherein the cover is attached to the connector housing by a hinge and is movable between an open position and a closed position. 
     
     
         4 . The electrical busbar connector in accordance with  claim 3 , wherein the cover and the connector housing define corresponding latching features configured to releasably retain the cover in the closed position. 
     
     
         5 . The electrical busbar connector in accordance with  claim 3 , wherein the cover further comprises a first threaded fastener configured to be received within a threaded hole in the connector housing. 
     
     
         6 . The electrical busbar connector in accordance with  claim 5 , wherein the cover further comprises a retainer configured to hold the first threaded fastener to the cover. 
     
     
         7 . The electrical busbar connector in accordance with  claim 6 , wherein the retainer defines a portal configured to allow a tool to access a head of the first threaded fastener. 
     
     
         8 . The electrical busbar connector in accordance with  claim 1 , further comprising:
 a second threaded fastener disposed within the cavity and configured to extend through an aperture in the electrical terminal and to attach the electrical terminal to a corresponding electrical terminal.   
     
     
         9 . The electrical busbar connector in accordance with  claim 8 , wherein a head of the second threaded fastener comprises an electrically insulative cap. 
     
     
         10 . The electrical busbar connector in accordance with  claim 9 , wherein the connector housing comprises an electrically insulative inner connector housing having retention features configured to retain the head of the second threaded fastener within the cavity and to retain the head of the second threaded fastener in a pre-staged position. 
     
     
         11 . The electrical busbar connector in accordance with  claim 10 , further comprising a third threaded fastener configured to secure the connector housing to a mating connector housing containing the corresponding electrical terminal. 
     
     
         12 . The electrical busbar connector in accordance with  claim 11 , wherein the connector housing defines a shroud encircling the electrical terminal which is configured to receive and interface with a perimeter seal of the mating connector housing, thereby sealing the connector housing to the mating connector housing. 
     
     
         13 . The electrical busbar connector in accordance with  claim 11 , wherein the connector housing defines a groove encircling the electrical terminal containing a face seal configured to interface with the mating connector housing, thereby sealing the connector housing to the mating connector housing. 
     
     
         14 . The electrical busbar connector in accordance with  claim 1 , wherein the electrical terminal has a plated surface comprising a material having a greater electrical conductivity than a material forming the electrical terminal. 
     
     
         15 . The electrical busbar connector in accordance with  claim 1 , wherein a portion of the electrical terminal is disposed within an aperture defined in the busbar. 
     
     
         16 . The electrical busbar connector in accordance with  claim 1 , wherein the electrical busbar is a first electrical busbar, wherein the electrical terminal is a first electrical terminal, wherein the connector housing is further configured to receive a second electrical busbar comprising the first electrically conductive material attached to a second electrical terminal comprising the second electrically conductive material. 
     
     
         17 . The electrical busbar connector in accordance with  claim 16 , wherein the first busbar and the second busbar each have a generally rectangular cross section, wherein uninsulated portions of the first busbar and the second busbar disposed within the connector housing are aligned along major axes of their rectangular cross sections and wherein insulated portions of the first busbar and the second busbar are aligned along minor axes of their rectangular cross sections. 
     
     
         18 . A method of manufacturing an electrical busbar assembly, comprising:
 welding an electrical terminal to an uninsulated portion of an electrical busbar;   inserting the electrical terminal within a cavity in an electrically insulative connector housing;   sealing an insulated portion of the electrical busbar to the connector housing;   inserting a threaded fastener through an aperture in the electrical terminal; and   attaching a cover to the connector housing configured to enclose the cavity, the cover comprising a cover seal configured to seal the cover to the connector housing.   
     
     
         19 . The method in accordance with  claim 18 , wherein the method further comprises:
 welding the electrical terminal to the uninsulated portion of the electrical busbar using torsion welding process.   
     
     
         20 . The method in accordance with  claim 18 , wherein the connector housing comprises retention features configured to retain a head of the threaded fastener within the cavity and wherein the method further comprises:
 retaining the head of the threaded fastener in a pre-staged position; and   overmolding an insulative cap over the head of the threaded fastener.